Flat surface-mounted multi-purpose wire

ABSTRACT

A multi-purpose wire includes at least one elongated conductor having a width of at least 0.125 inches. The conductor includes at least one conductive layer having a thickness no greater than about 0.0200 inches. The wire also includes a bonding material between each conductor, and an insulation layer surrounding the conductor and bonding material.

This application is a continuation of application Ser. No. 08/942,305filed Oct 1, 1997 now abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to flat wiring, and moreparticularly, to a thin, bendable, surface-mounted flat wire for use ina variety of wiring applications.

2. Description of the Related Art

Current wiring and re-wiring techniques and procedures present manylimitations to the user in existing commercial or residentialapplications. The choices for adding, changing or moving any of the manywiring applications—electrical, telephone, antenna/CATV, loud speaker,and low voltage wiring, as well as the associated plugs, switches, andconnections—is expensive or obtrusive or both.

Temporary or removable methods such as extension cords, long telephoneand antenna/CATV cords, external loud speaker wire, and low voltagewire, are cumbersome and hard to hide or blend into a room.

Permanent installations typically require either a professional toinstall in a wall if the user desires a hidden installation or the useof some type of unattractive and inflexible conduit. Both methods tendto be expensive.

In light of the foregoing, there exists a need for a permanent,non-obtrusive, low-cost, easy to self-install, location specific, hiddensystem for wiring and re-wiring applications on walls and ceilings.There also exists a need for associated plugs, switches, and connectionsthat could provide an interface between such a new wiring system andconventional wiring.

SUMMARY OF THE INVENTION

The present invention is directed to flat, thin, flexible, multi-layeredwires, which substantially obviate one or more of the problems due tothe limitations and disadvantages of the related art.

By way of example and not by limitation, the present invention can beutilized in a wide variety of applications, including: standardelectrical wiring; telephone wiring; loud speaker wiring; low voltagewiring such as security systems; under surface lighting; and cable TVwiring.

In addition, the present invention includes several unique outlets,switches, and connectors that provide the interface between existingconventional round wiring and the flat wires of the present invention.

To achieve these and other advantages and in accordance with the purposeof the invention, as embodied and broadly described, the inventionprovides for a surface mounted, flexible, multi-purpose wire,comprising, a plurality of flat elongated conductors spaced apart in agenerally parallel relationship, wherein each of the plurality of flatconductors comprises a plurality of copper layers; an adhesive materialseparating the plurality of flat conductors; and an insulation layersurrounding the flat conductors and the adhesive material, wherein theadhesive material bonds to the insulation layer; and wherein across-sectional height of the flat conductors and insulation layer issuch that the multi-purpose wire will blend in with the surface whenpainted or after wallpaper is applied.

The copper layers are generally on the order of about 0.002 inchesthick, but may range from about 0.0004 to 0.020 inches. The number andthickness of the copper layers may be adjusted to suit the desiredapplication. It is understood that the various dimensions describedherein may vary considerably within the practice of this invention.

The insulation layer can be composed of materials selected form thegroup consisting of polyester films (e.g., Dupont Mylar), urethanefilms, or teflon films. The adhesive material can be selected from thegroup consisting of adhesive tape (e.g., 3M 9500PC), liquid adhesive, ora combination of the two.

In another aspect, the invention provides for a surface mounted,flexible, multi-purpose wire, comprising a single flat conductortogether with the adhesive material and insulation layers as describedabove.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, aspects and advantages will be betterunderstood from the following detailed description of a preferredembodiment of the invention with reference to the drawings, in which:

FIG. 1 is an exploded side cross-sectional view of a 3-wire flatconductor for use in standard electrical wiring applications;

FIG. 2 is an exploded side cross-sectional view of a 5-wire flatconductor for use in applications requiring two circuits;

FIG. 3 is an exploded side cross-sectional view of a 2-wire flatconductor for use in loud speaker systems;

FIG. 4 is an exploded side cross-sectional view of a 6-wire flatconductor for use in telephone applications;

FIG. 5 is an exploded side cross-sectional view of a 2-wire flatconductor for CATV applications;

FIG. 6 is an exploded side cross-sectional view of a 2-wire flatconductor for use in low voltage applications;

FIG. 7 is a perspective configuration view of the pluggable andstand-alone outlets connected via a flat wire;

FIG. 8A is an exploded perspective view of the components of the outletassembly of the present invention;

FIG. 8B is an alternate exploded perspective view of the components ofthe outlet assembly of the present invention;

FIG. 8C is a perspective view of the underside of a fully configuredoutlet assembly of the present invention;

FIG. 9A is a perspective view of the flat-wire to outlet frame connectorinterface in accordance with the present invention;

FIGS. 9B, 9C, and 9D provide top, side, and bottom views, respectively,of the flat-wire to outlet frame connector interface in FIG. 9A;

FIG. 9E is a perspective view of the underside of the flat-wire tooutlet frame connector of FIG. 9A showing the elongated slots andwipers;

FIG. 10A is perspective view of the flat-wire to conventional-wireconnector in accordance with the present invention;

FIGS. 10B, 10C, and 10D provide top, side, and bottom views,respectively, of the flat-wire to conventional-wire connector in FIG.10A;

FIG. 11A is a three dimensional perspective view of a three wiper femaleplug receptacle system according to the present invention;

FIGS. 11B and 11C are front and side perspective views, respectively, ofa side mounted switch;

FIG. 12A is a perspective view of the surfaced mounted flat wireconnected to a ceiling fan;

FIG. 12B is a perspective view of the discrete wired switch embodimentin accordance with the present invention;

FIG. 13 is a diagrammatical representation of a flat wire/loud speakersystem configuration;

FIG. 14 is a diagrammatical representation of a flat wire/phone jacksystem configuration;

FIG. 15 is a diagrammatical representation of a flat wire/CATV systemconfiguration;

FIG. 16 is a diagrammatical representation of a flat wire/embedded lightsystem configuration;

FIG. 17 is a diagrammatical representation of a flat wire/DC powersystem configuration;

FIG. 18 is a diagrammatical representation of a GFI detection circuitfor 4 outlets and 3 terminals without a switchable input plug;

FIG. 19 is a diagrammatical representation of a GFI detection circuitfor 8 outlets without a switchable input plug; and

FIG. 20 is a diagrammatical representation of a GFI detection circuitfor 8 outlets with a switchable input plug.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

In general, as stated above, the present invention can be used or beadapted to perform in a wide variety of applications including: standardelectrical wiring; telephone wiring; loud speaker wiring; low voltagewiring applications such as intercoms and security systems; undersurface lighting; and cable TV wiring. In addition, the presentinvention includes several unique outlets and switches that interfacewith existing conventional round wiring. Moreover, the present inventionalso utilizes tape, stripping tools, and unique connectors to implementa particular system embodiment. Each of the individual components willbe discussed in greater detail, followed by a description of theapplications to which the present disclosure is directed.

Each of the individual wire embodiments share a basic common structure.However, depending on the particular application, various modificationscan be made to the basic structure and the dimensions of the structuralcomponents to achieve the desired purpose.

For ease of reference, the basic structure will be discussed in detailwith reference to the first wire embodiment. It is understood that thisbasic structural concept applies to all the wire embodiments.Modifications to the basic structure will be discussed whereappropriate. Like reference numbers will be used where possible to referto similar parts throughout the drawings.

Wire Embodiments Alternating Current (AC) Electrical Wire

Referring now to the drawings, and more particularly to FIG. 1, there isshown an exploded side cross-sectional view of a standard 110 VAC3-conductor wire embodiment in accordance with the present invention.The exploded cross-sectional view is for illustrative and discussionpurposes only. In the actual 3-conductor embodiment, there would be novisible spacings (i.e., the white areas in FIG. 1) between theconductors, insulation, and adhesives components, each of which isdescribed further below.

Generally, the electrical wire 10 is a flat, flexible, wire that allowsthe user to bring electricity to any area of a wall or ceiling in aroom. The electrical wire 10 is mounted to the surface of the wall orceiling, thereby eliminating the need for costly inner wall or ceilingrewiring. The wire may be painted or papered over to match the rest ofthe surface.

The electrical wire 10 comprises a plurality of elongated and parallelspaced multi-layer conductors 11. As shown in FIG. 1, a typical 110 VAC3-wire embodiment would include an AC ground conductor, an AC neutralconductor, and an AC power conductor.

An internal adhesive material 13 separates the flat conductors 11 aswell as providing edge sealing of the outer flat conductors as shown inFIG. 1. The adhesive material 13 and conductors 11 are surrounded by athin layer of insulation material 15. In addition, an external adhesivelayer 17 is applied to the back of the flat wire to attach theelectrical wiring to the desired surface.

Each of the conductors 11 are comprised of one or a plurality of layersmade with a copper material that is about 0.0004 to about 0.020 inchesthick, and preferably on the order of about 0.002 inches thick. Threecopper layers 11a, 11b, and 11c, are shown in FIG. 1 for example. Theconductor layer thickness should be consistent across its length andwidth, thereby eliminating any resistance “hot spots”.

The current and or signal carrying specifications of a particularapplication may be accomplished in any of three ways, eitherindividually or in combination. First, the width ‘w_(c)’ of theconductors 11 may be varied. Second, additional thin copper layers maybe stacked for each conductor 11. Third, the thickness ‘t’ of theconductor 11 may be increased.

For most load and current applications, each conductor will generally becomposed of about 2-5 layers of copper. It is understood, however, thatutilizing more or less layers, for each of the below disclosedembodiments, is within the scope of this invention.

For example, a five copper layer conductor, where each copper layer isabout 0.002 inches thick, will be on the order of 0.012 inches thickincluding insulation. Even at that thickness, however, the flat wirepresents an extremely thin cross-section that is virtually undetectableon a surface once painted or papered over.

The insulation layer 15 will now be described in greater detail.Insulation is achieved with minimum thickness to prevent conductionunder ideal conditions only. The primary purpose of the insulation layer15 is to assist in the optical occlusion of the presence of the wire asapplied to a surface so that a pleasing appearance can be achieved uponinstallation.

The insulation layer 15 also orients the copper conductive layers. Inaddition, the insulation material may be used alone, or in combinationwith the internal adhesive 13, to separate the conductive layer groupsand maintain a safe dielectric distance between conductors of differentpurposes (e.g., AC ground vs AC neutral or AC power conductors).

As shown in FIG. 1, the insulation layer 15 at the edges of themulti-layered flat wire 10 may be, but need not be, tapered tofacilitate the optical occlusion. The insulative material may beselected from the group consisting of, for example, polyester films(e.g., Dupont Mylar), urethane films, or teflon films.

It is understood that additional insulative materials are considered tobe within the scope of this invention and may be used so long as theinsulation is compliant, paintable, and bondable to surfaces. Theinsulation should also be compatible with joint compounds, be UVtolerant, and have similar thermal expansion and contractioncharacteristics as that of the conductors and the surface to which it isadhered.

Other desirable properties are that the insulation should withstandtensile forces applied in the fabrication process, not retract or relaxunder storage conditions, and be removable when its use is completed.

Any abrasion, cracking, cutting, piercing, or any other insulationdamage—that would render an unsafe exposure to electrical harm—will bemade safe using electronic means of failure detection that willdisconnect harmful currents from the user in a time frame that willprevent permanent harm. This electronic failure detection means, orGround Fault Interrupter (GFI) circuit, is discussed in greater detaillater in the specification.

Returning to FIG. 1, the internal adhesive material 13 must be able tobond to the insulation layer 15. For example, adhesive tape (e.g., 3M9500PC), liquid adhesive, or a combination of the two, may be used as aninternal adhesive. The internal adhesive material 13 will also functionto separate the conductive layer groups and maintain a safe dielectricdistance between conductors of different purposes. In addition, theadhesive 13 can even out gaps in the various components within the wireto aid in its ability to visually disappear on a surface.

The thickness of the internal adhesive material 13 closely approximatesthe cross-sectional height ‘t’ of the conductors 11, especially wherethe internal adhesive separates the conductors 11. As shown in FIG. 1,the internal adhesive 13 may be tapered at the edges of the flat wire 10to facilitate the optical occlusion.

An external adhesive layer 17 is provided for attaching the wire to thedesired surface. The external adhesive layer 17 could be, for example,two-sided tape, with one side being fixed to the back of the flat wire10 and the other to the wall or surface. Alternatively, a chemicaladhesive may be applied separately, and may consist of any of theadhesives with good bonding qualities to both the insulation layer 15and the desired surface to which the flat wire 10 is adhered.

A finished flat 3-conductor wire 10, having, for example, three copperlayers of 0.002 inch thickness, would be approximately 0.007 to 0.010inches in cross-sectional height ‘t’. For a 15 amp rated wire, theentire width ‘W’ of the 3-conductor flat wire 10 is on the order ofabout 2.0-2.5 inches. The width ‘w_(c)’ of each conductor is about0.4-0.6 inches, and the spacing between conductors ‘w_(s)’ is about0.2-0.3 inches.

To ensure readily identifiable, proper and safe connections, the width‘w_(c)’ of the AC ground conductor could be increase slightly ascompared to the AC neutral and AC power conductors. The width of the ACground conductor would therefore be closer to 0.6 inches, while thewidths of the other two conductors would be closer to 0.4 inches.Alternatively, the width of the AC ground conductor could be reduced ascompared to the other conductors.

Similar dimensions would be useful for other applications, however, itis understood that the various dimensions can vary considerably withinthe practice of this invention.

The flat wire 10 provides a simple, low cost alternative to expensiverewiring jobs for supplying electricity to specific locations of wallsand ceilings for use in fans, ceiling lighting, or wall or art lighting.

In FIG. 2, there is shown an exploded side cross-sectional view of a 110VAC 5-conductor wire 20 of the present invention, having 5 parallelspaced multi-layered copper conductors 11. This 5-conductor wireembodiment includes all of the features of the 3-conductor wireembodiment disclosed above, with the addition of two conductors 11 toaccommodate a second circuit. Like or similar parts are identified bythe same reference numerals.

The 110 VAC 5-conductor wire is used where two circuits on one flat wireare desirable, such as a wire leading to a light and a fan, or where aswitched plug is used. In this embodiment the five conductors consist oftwo AC neutral conductors, two AC power conductors, and a single ACground conductor.

The number and thickness of the copper layers, the width ‘w_(c)’ andthickness ‘t’ of the conductors 11, and the spacing between theconductors ‘w_(s)’ are generally of the same dimensions as that of the110 VAC 3-conductor wire. The overall width ‘W’ of the finished flatwire 20 is on the order of about 3.5-4.25 inches.

The flat wire conductors of the present invention may also be utilizedto construct a 220 VAC wire embodiment, generally as shown withreference to FIG. 1. A finished flat 3-conductor 220 VAC wire, having,for example, four copper layers of about 0.002 inch thickness, would beapproximately 0.012 inches in cross-sectional height ‘t’. The entirewidth ‘W’ would be on the order of about 3.0-3.5 inches. The width‘w_(c)’ of the neutral and power conductors is about 0.4-0.6 inches,while the width ‘w_(c)’ of the ground conductors is about 0.2-0.4inches. The spacing between conductors ‘w_(s)’ is about 0.4-0.6 inches.

As in the 3-conductor 110 VAC electrical wire, the difference in groundconductor width in the 3-conductor 220 VAC electrical wire is tofacilitate proper connection of the wires to the connectors.

Loud Speaker Wire

As with the previous embodiments, the loud speaker wire 30 of thepresent invention, illustrated in FIG. 3, is a flat, thin, flexible,wire that allows the user to position loud speakers at any area of awall or ceiling in a room. The loud speaker wire 30 may be used, forexample, with stereo or mono audio components, or for wiring externalspeakers for enhanced television or sound systems such as “surroundsound”.

The loud speaker wire 30 can be mounted to the surface of a wall orceiling, thereby eliminating the need for costly inner wall or ceilingrewiring. The wire may also be painted or papered over to match the restof the surface.

Referring to FIG. 3, the thin loud speaker wire 30 is comprised of apair of multi-layered copper conductors 11. The conductive capacity ofthe loud speaker wire 30 is preferably equivalent to 10 gauge strandedwire. Each of the conductors 11 would generally have two or three copperlayers, the former being shown by copper layers 11a and 11b in FIG. 3.The copper layers are about 0.0004 to about 0.020 inches thick, andpreferably on the order of about 0.002 inches thick. It is understoodthat depending on the particular application, more or less copper layersmay be utilized.

The pair of conductors 11 are separated by an appropriate adhesivematerial 13 and both are surrounded by an insulation layer 15 asdiscussed above. Similar insulation and adhesives may be used aspreviously described above.

Because of its application, the loud speaker wire 30 may also include ashielding material 18 surrounding the conductors 11 to reduce outsidesignal and cross-over interference. The shielding material 18 may be oneor a plurality of layers of any suitable metallic or semi-metallicshielding materials, for example, aluminum or metalized polyester films.

The finished loud speaker wire 30 is approximately 0.008 inches incross-sectional height ‘t’ with three copper layers, with an overallwidth ‘W’ of about 2.5-3.0 inches. The width ‘w_(c)’ of each conductoris about 0.6-0.8 inches, and the spacing between the conductors ‘w_(s)’is about 0.2-0.3 inches.

As shown in FIG. 3, the edges of the wire 30 may be tapered tofacilitate the optical occlusion. A similar external adhesive layer 17as that previously described is also provided to attach the loud speakerwire 30 to the appropriate surface.

Telephone Wire

An illustrative example of a telephone wire embodiment 40 according tothe present invention is shown in FIG. 4. In this embodiment, sixmulti-layered copper conductors 11 are provided, separated by adhesivematerial 13, and surrounded by insulation layer 15. A six conductor wirefacilitates the use of Private Branch Exchange (PBX) switching, therebyproviding a private telecommunications exchange that includes access toa public telecommunications exchange. The conductors 11 are functionallyequivalent to standard 22 gauge telephone wire.

Two, four, and eight multi-layered copper conductor telephone wires mayalso be utilized. Moreover, the eight conductor embodiment approximatesfour twisted pair wires (e.g., unshielded twisted pair (UTP) wire),which may be suitable for carrying data.

Each of the conductors 11 would generally have two or three copperlayers, the former being shown by copper layers 11a and 11b in FIG. 4.The copper layers are about 0.0004 to about 0.020 inches thick, andpreferably on the order of about 0.002 inches thick. It is understoodthat, depending on the particular application, more or less copperlayers may be utilized.

The finished telephone wire 40, with three copper layers, isapproximately 0.008 inches in cross-sectional height ‘t’, with anoverall width ‘W’ of about 1.5-3.5 inches, depending on the number ofconductors 11 utilized. The width ‘w_(c)’ of each conductor is about0.2-0.4 inches, and the spacing between the conductors ‘w_(s)’ is about0.125-0.25 inches.

As shown in FIG. 4, the edges of the wire 40 may be tapered tofacilitate the optical occlusion. A similar external adhesive layer 17as that previously described is also provided to attach the telephonewire 40 to the appropriate surface.

Cable Television CATV Wire

An illustrative example of a cable television CATV wire embodiment 50 inaccordance with the present invention is shown in FIG. 5. In thisembodiment, a pair of conductors 11 are provided, each of which maygenerally have two or three copper layers, the former being shown bycopper layers 11a and 11b in FIG. 5. The copper layers are about 0.0004to about 0.020 inches thick, and preferably on the order of about 0.002inches thick. It is understood that, depending on the particularapplication, more or less copper layers may be utilized.

As in the previous embodiments, the conductors 11 are separated byadhesive material 13, and surrounded by insulation layer 15. As shown inFIG. 5, the edges of the wire 50 may be tapered to facilitate theoptical occlusion. A similar external adhesive layer 17 as thatpreviously described is also provided to attach the wire 50 to theappropriate surface.

The finished antenna/CATV wire 50, with three copper layers, isapproximately 0.008 inches in cross-sectional height ‘t’, with anoverall width ‘W’ of about 1.8-2.2 inches. The width ‘w_(c)’ of eachconductor is about 0.4-0.6 inches. As shown in FIG. 5, the spacingbetween the conductors ‘w_(s)’ is about 0.4-0.6 inches, which issomewhat larger than in previous embodiments in order to reduce radiofrequency interference and improve transmission quality. The CATV wireis rated at 300 ohms.

Low Voltage Wire Applications

FIG. 6 illustrates a low voltage wire embodiment 60 in accordance withthe present invention. Such low voltage (direct current) applicationswould include intercoms, security systems, and “smart house products”.As shown in FIG. 6, two DC power conductors 11 are shown. The structureof the conductors 11 is essentially the same as the multi-layerconductors 11 described earlier. The internal adhesive material 13,insulation layer 15, and external adhesive layer 17, would be the samein this embodiment as those described previously.

Each of the conductors 11 would generally have two or three copperlayers, the later being shown by copper layers 11a, 11b, and 11c in FIG.6. The copper layers are about 0.0004 to about 0.020 inches thick, andpreferably on the order of about 0.002 inches thick. It is understoodthat, depending on the particular application, more or less copperlayers may be utilized.

The finished low voltage wire 60, with three copper layers, isapproximately 0.008 inches in cross-sectional height ‘t’, with anoverall width ‘W’ of about 1.2-1.6 inches. The width ‘w_(c)’ of eachconductor is about 0.3-0.5 inches, and the spacing between theconductors ‘w_(s)’ is about 0.2-0.3 inches.

As shown in FIG. 6, the edges of the wire 60 may be tapered tofacilitate the optical occlusion. A similar external adhesive layer 17as that previously described is also provided to attach the telephonewire 60 to the appropriate surface.

Under Surface Lighting Wire

While the thin, flexible wire for under surface lighting is similar inconstruction to the 110 VAC 3-conductor and 5-conductor wire embodimentsdescribed above, it is unique in that the under surface lighting wireincorporates embedded lights 169. See FIG. 16. This allows the user toinstall the lighting under a surface of a cabinet, shelf, or otherlocations where under surface lighting is desired. This embodiment willbe described in greater detail in the discussions of the conventionalwire-to-flat wire system implementations later in the specification.

Outlets and Connectors

The present invention encompasses a family of outlets that provideconnection points between the flat wires of the present invention andconventional existing electrical outlets and conventional round wiresystems. These connecting outlets are of two general types, with onebeing directly “pluggable” into a conventional existing outlets, whilethe other is a “stand-alone” surface mounted unit.

The pluggable connecting outlets will always provide the compatibilityinterface between the standard household electric wiring apparatus andthe various embodiments of the flat wires in accordance with the presentinvention. Accordingly, the pluggable outlet is always at the source ofthe standard electrical current. The stand-alone unit interfaces withthe pluggable unit via the various flat wire embodiments of the presentinvention.

FIG. 7 illustrates the typical configuration interface between thepluggable and stand-alone units. Assuming that a conventional two-femalereceptacle outlet, as fed by conventional round wire 69 from behind thewall 66, is located behind outlet 65. Outlet 65 would therefore be ofthe directly “pluggable” variety. Outlet 67 would thus be a stand-aloneoutlet that is affixed to the wall without a plug attachment. Thestand-alone outlet can therefore be placed anywhere in the room,regardless of the location of the existing outlets.

In the electrical wire embodiments, for example, current from theconventional wire 69 is transferred to the stand-alone outlet 67 viapluggable outlet 65 and the flat 110 VAC wire 68 of the presentinvention.

FIG. 8A is an exploded perspective view of the pluggable outlet unit 65,depicting the various internal and external components of the outlet. Asshown, the outlet 65 contains side mounted female receptacles 72 and 73housed within an outlet cover 74. Alternatively, the female receptacles72 and 73 may be mounted in the front as in standard outletconfigurations. The side mounted receptacle version has an advantage inthat the outlet cover 74 may be painted or papered to blend into thesurface. Also, additional female receptacles 72′ and 73′ may be locatedon another side of the outlet cover 74 as in FIG. 8B, which shows fourfemale receptacles.

The outlet base 75 for the pluggable outlet 65 contains openings 75a and75b that would be positioned over the female receptacles of theconventional existing outlet, and affixed to the surface with screws orother equivalent attachment devices. The outlet cover 74 would then beplaced over the base 75.

The pluggable outlet 65 also contains a flat wire connector 76 and aGround Fault Interrupter (GFI) module 77 with its associated GFI resetbutton 78. The GFI module 77 (the operation of which is discussed laterin the specification) contains two sets of male contacts 79 and 79′ thatpass through the openings 75a and 75b to plug into the respective femalereceptacles associated with conventional wiring systems. The GFI module77 functions to interrupt the electric current to the load in the eventthe flat wire is pierced or cracked. FIG. 8C provides a perspective viewof the underside of a completed pluggable outlet assembly 65, depictingthe GFI male contacts 79 and 79′ extending through the base member 75through openings 75a and 75b.

The stand-alone outlet 67 (see FIG. 7) differs from the pluggable outlet65 in two respects. First there is no need to provide for a GFI module77 and its associated reset button 78 in the stand-alone outlet. Second,the stand-alone outlet's base 75 does not need openings 75a and 75b asthe stand-alone outlet does not interface directly with the conventionalwiring system. In all other respects, the pluggable and stand-aloneoutlets are the same.

A single outlet base 75 may be configured with “punch out” openings 75aand 75b so that it may be used with either the pluggable or stand-aloneoutlet assemblies.

FIG. 8B is an alternate perspective view of the pluggable outlet unit65, depicting the two sets of male contacts 81 and 83, which interfacewith the flat wire connector 76 and GFI module 77, respectively. Notethat the flat wire connector 76 and GFI module 77 are not affixed to thebase member 75, but are selectively connected to the outlet cover 74 bythe male contacts 81 and 83.

Also depicted in FIG. 8B is copper frame 84 on the underside of cover74. The copper frame 84 functions to provide conductive connections tofemale receptacles 72, 72′, 73, and 73′, and the two sets of malecontacts 81 and 83. The male contacts 83 plug into corresponding slots82 on one surface of the GFI module 77 as shown in FIG. 8A.

The flat wire connector 76, which is common to both the stand-alone andpluggable outlets, will now be discussed in greater detail. The flatwire connector 76 provides the connection point between the flat wiresof the present invention and the copper outlet frame 84.

An example of such a “flat-wire to outlet frame” connector 90 isillustrated in the perspective view of FIG. 9A. While a 5-conductorconnector assembly is shown for illustrative purposes, it is understoodthat the connector can be constructed to interface with any number offlat conductors having any number of copper layers.

Along one surface of connector 90 there is provided a plurality of flatwire receptacles 92 for receiving each of the flat wire conductors 11.The 3-conductor and 5-conductor electrical wires may use the same5-conductor connector assembly 90, provided the outer wire receptaclesare depopulated when the 3-conductor electrical wire is used. The otherwire embodiments would have their own interface connectors 90. The needfor multiple connectors does not pose a problem as the connectors caneasily be swapped and inserted in the outlet cover 74 by plugging theconnector into the male contacts 81 fixed to the outlet cover 74.

Each of the flat wire receptacles contains a plurality of slottedsprings 94 for contacting the corresponding copper layers in each of themulti-layer conductors 11 (see FIG. 9B also). Two to five slottedsprings 94 would generally be provided to correspond to the multi-layercopper conductor embodiments discussed above.

As shown in the perspective views in FIGS. 9A and 9E, and the side viewin FIG. 9C, a plurality of elongated female slots 98 are contained onanother surface of the connector 90. These elongated female slots 98interface with the corresponding set of male contacts 81 as shown inFIG. 8B. The male contacts 81 merely slide into slots 98 to make theconnection.

As more clearly seen in FIG. 9E, each of the extended slots 98 contain aseries of wipers or brushes 98a-98d, each of which moves independentlyof the others, to provide a better connection and more surface contactwith the male contacts 81.

The sequence of connecting the flat wire to the connector 90 isdescribed with reference to an exemplary 5-conductor embodiment whereeach of the conductors has three copper layers. First, each conductor 11is lined up with a respective flat wire receptacle 92. Then, each copperlayer for each of the conductors 11 is inserted between the slottedsprings 94. The slotted springs 94 are slightly biased by screws 96 asshown in FIG. 9D. By tightening the screws, one can ensure that both thetop and bottom of each copper layer are in contact with the slottedsprings. This ensures the best conductor contact, and also ensures thateach copper layer (and thus each conductor) experiences the sameresistance.

Finally, the male contacts 81 and extended female slots 98 are lined upand the connection to either the pluggable or stand-alone outlet ismade. The outlet cover 74 would have a small cutout at the edge facingthe flat wire receptacles 92 of connector 90 to enable the flat wires topass through the outlet cover 74 to reach the connector 90.

In addition to the flat-wire to outlet frame connector, a secondconnector type is also needed to provide an interface betweenconventional round wires and the various flat wire embodiments describedabove. This would occur, for example, where the flat wires connect to awall light, fan, or intercom system.

An example of such a connector 100 is illustrated in the perspectiveview of FIG. 10A, which depicts a 5-conductor flat-wire to conventionalwire connector. While a 5-conductor connector is shown for illustrativepurposes, it is understood that the connector can be constructed tointerface with any number of flat conductors and any number ofconventional round wires. The 3-conductor and 5-conductor electricalwires may use the same 5-conductor connector assembly 100, provided theouter wire receptacles are depopulated when the 3-conductor electricalwire is used. The other wire embodiments would have their own interfaceconnectors 100.

As shown in FIG. 10A, connector 100 contains a plurality of conventionalset screws 101 along one surface of the connector to provide aninterface for the standard “wire wrap” connections common inconventional round wiring systems (see FIG. 10B also). Along anothersurface are placed one or more flat wire receptacles 102 for receivingeach of the flat wire conductors. Each of the flat wire receptacles 102contains a plurality of slotted springs 104 (see FIG. 10D also) forcontacting each of the layers in each of the multi-layer conductors. Theslotted springs 104 are slightly biased by screws 96 as shown in FIGS.10A and 10C and function in the same way as that described with respectto the connector 90. Connection to the flat-wire receptacles by the flatwire conductors is the same as that discussed with regard to connector90.

FIG. 11A depicts an improved three wiper female receptacle 110, whichmay be incorporated into the pluggable 65 or stand-alone 67 outlets ofthe present invention.

Receptacle 110 contains cast copper leads 111 and 112 that contact therespective wiper assemblies 114 and 116. Each of the wiper assembliescontains three wipers (114a, 114b, 114c; 116a, 116b, 116c), each ofwhich moves independently of the other two in the respective assembly.

The three-wiper receptacle 110 thus provides a better connection andmore surface contact with the copper leads 111 and 112. The other endsof copper leads 111 and 112 extend to the copper frame 84 (see FIG. 8B).In addition, since the three wipers move independently, the receptacleis better able to accommodate torque in a plug.

Switches

A unique set of switches 124′ are provided for use with the wireproducts of the present invention. The switches may be electricallywired to an existing switch, or plugged into an existing outlet, oroperated by radio frequency (RF) remote power. The switches are usedmainly with the 3-conductor and 5-conductor wires, and under-surfacelighting embodiments described above.

The switch mechanism may be front or side mounted (FIGS. 11B and 11C)and many switch variations are contemplated, including:

-   -   (1) toggle controlled, permanent mount, discrete wired;    -   (2) capacitive touch or membrane switch controlled, permanent        mount, discrete wired;    -   (3) capacitive touch or membrane switch controlled, permanent        mount, radio frequency (RF) sender/receiver pair;    -   (4) capacitive touch or membrane switch controlled, hand held or        wall hung, RF sender/receiver pair; or    -   (5) capacitive touch or membrane switch controlled full dimmer        set with indicators, hand held or wall hung, RF sender/receiver        pair.

Regardless of the particular type of switch utilized, however, all ofthe switches share certain common elements. The switches 124′ (see FIG.12B) do not switch the AC circuit. Rather, they send a signal, via a lowvoltage wire 125 (12 VDC) as shown in FIG. 12B, to the correspondingplug that will switch the AC circuit.

If the switch unit is hardwired, it is coupled via voltage circuits.This makes the switches incapable of being used without a compatibleplug unit.

Tools

The unique thin, flat wires of the present invention require equallyunique insulation stripping tools to facilitate attachment to connectorsand existing outlets. Each wire embodiment described above will have itsown specialized tools.

Two versions are contemplated—one directed to use by professionalelectricians or installers and the other to non-professionals. Theprofessional stripping tool is designed to cut and strip the insulationlayer 17 off the conductors 11 in a single procedure similar to themanner of operating a conventional stripping tool. Considering the smallthicknesses of the conductors, it is apparent that the stripping tool beprecisely milled to allow for such precision cutting and stripping. Suchprecise milling may tend to raise the cost of such a tool, making iteconomically feasible for professional use only.

A second slicing tool directed to the non-professional will align thewire in the stripper and slice adjacent and perpendicular to theconductors, to allow the user to strip away the necessary insulationmaterial to get to the conductive layers. The insulation is then peeledback and removed by scissors.

System Applications

A general illustrative system embodiment—incorporating the variouswires, outlets, switches, and connectors described above—is shown inFIG. 12A.

With reference to FIG. 12A, there is provided a conventional outlet 120and conventional switch 124. A person desirous of wiring a ceiling fan126 in the location shown would normally have to engage in an expensivewall and ceiling wiring job to bring electric current to the subjectfan.

By utilizing the flat wires, outlets, switches, and connectors of thepresent invention, however, the task is greatly simplified as is nowdescribed. First a pluggable outlet 65 (FIG. 8A) is plugged into theconventional outlet 120. Next a stand-alone outlet 67 is fastened to thewall in the desired location. Lengths of flat wire 123 (e.g.,3-conductor or 5-conductor 110 VAC) are run between the pluggable outlet65 and stand-alone outlet 67, and again between stand-alone outlet 67and the fan.

A connector 90 (not shown in FIG. 12A, but is of the type depicted inFIG. 9A) connects the flat wires 123 to the pluggable and stand-aloneoutlets 65 and 67. In addition, another connector 100 (of the typedepicted in FIG. 10A) connects the conventional round wires of the fan126 with the flat wire 123.

The flat wire 123 is affixed to the wall surface with the adhesive layer17 as described above, typically double sided tape, and either paintedor papered over to obscure the wire.

As illustrated, the flexible, flat wire 123 incurs a 90 degree bendalong its width at point 127 where the ceiling and wall adjoin, as theflat wire is adhered to a different planar surface. In addition tobending at any angle along its width to accommodate different planarsurface joints, the flexible wire may actually be bent back upon itselfat any angle to accommodate angle changes on the same planar surface.

Consider, for example, the second wall lighting, apparatus 126′ in FIG.12A. The wall light 126′ is connected to standard switch 124 by a flatwire 128. For aesthetic reasons, rather than put a second stand-aloneswitch near the conventional switch, the flat wire is bent at a 45degree angle at points 129 and 129′. The flat wire is basically foldedback upon itself to achieve the 45 degree turn.

FIGS. 13-17 are more specific diagrammatic representations of thevarious system embodiment using the flat wires previously disclosed. Thesystems are briefly described below.

FIG. 13 illustrates the flat wire/conventional loud speaker wireinterface. For simplicity and ease of illustration, only one speaker 131is illustrated with stereo 130. It is understood that any number ofspeakers may be used with the flat wires of the present invention.

As illustrated, stereo system 130 is connected to speaker 131 via flatwires 133. The speaker 131 can be placed in any desired location. Thetraditional speaker wires 136 are then connected to a stand-alone plugon the wall. A second stand-alone plug is placed in the desired locationnear the new speaker position. The flat wires 133 are then run betweenthe two stand-alone plugs. The entire length of the flat wire 133 maythen be painted or papered over, thereby eliminating unsightly andcumbersome speaker wire.

With reference to FIG. 14, there is shown a diagrammatic representationof the application of the flat wire/conventional phone jack interfacefor use in providing a connection to an extension phone.

As illustrated, the existing phone jack or phone receptacle 141 isconnected to the extension phone jack 142 via flat wires 143. As shown,a flat wire phone apparatus 147 is connected to the existing phone jack141. The extension phone jack 142 is then placed in the desired locationand connected to flat wire phone apparatus 147′. The flat wires 143 arethen connected between the flat wire phone apparatuses 147 and 147′. Theentire length of the flat wire 143 may then be painted or papered over,thereby eliminating unsightly and cumbersome phone wire.

A diagrammatic representation of a CATV application is shown in FIG. 15.The cable input 151 is fed into the house via the 75 ohm coaxial cable158. The cable 158 is then connected to 75 ohm-300 ohm conversionapparatus 157 located on the wall near the input 151 into the house. Asecond conversion apparatus 157 is placed near the desired television152 location. Flat wires 153 are then run between the two conversionapparatuses. As above, the entire length of the flat wire 153 may thenbe painted or papered over, thereby eliminating unsightly and cumbersomeCATV wire.

The under surface lighting embodiment, including flat wires 163 withembedded lights 169, is shown in FIG. 16. The switch or plug 161 isconnected to the flat wire 163. The embedded lights 169, may be, forexample, double-ended RSC base 120V halogen lamp from 20 to 100 watts.The flat wires can be placed in any under surface location whereadditional light is desired, such as under a cabinet or shelf. The flatwire 163 may then be painted or papered over to match the rest of thesurface.

The flat wires of the present invention may also be used with directcurrent (DC) applications. With reference to FIG. 17, a DC source 171 isconnected to a DC outlet 172, via flat wires 173. As in the other systemembodiments, wall connectors provide the interface between theconventional DC wires 158 and flat wires 153.

Ground Fault Interruption (GFI) Circuit

Since the flat wire is nearly invisible after it is painted or paperedover, there is a possibility that at some later date, a person couldinadvertently drive a nail or picture hook through the flat wire, orotherwise cut the wire.

In each of the systems, therefore, a ground fault interruption (GFI)module(s) 77 (see FIGS. 8A-8C) will be provided as a safety measure toprevent injury should accidental penetration through the ultra thinlayers of insulation occur. The term ground fault comes from anything orany person providing a ground path other than the normal internalground.

The GFI circuit will monitor the current flow through the power andneutral conductors of the AC circuits, and if more than ten milliampereof mismatch is sensed, then both conductors will be disconnected by acircuit breaker. The circuit breaker will be fast enough to prevent anypermanently harmful discharge.

The circuits will provide a fail safe methodology such that any circuitswill be checked before connection and rechecked after connection. Powerfrom the circuit will provide connection so that a circuit failure willresult in no power beyond the circuit breaker.

As described previously, the circuit is physically located in the“pluggable” outlet 65 (see FIGS. 8A-8C) that plugs into a conventionalwall outlet as discussed above. The GFI detection circuit is basically arelay that is normally closed. When the fault current to ground exceedssome predetermined value that is less than that required to operate theovercurrent protective device of the supply circuit, the relay opens,interrupting the electric current to the load.

FIG. 18 illustrates a standard single circuit 180 non-switchabletwo-plug system having a GFI detection circuit connected to a 4-plug,3-terminal apparatus in accordance with the present invention.

FIG. 19 illustrates a standard single circuit 190 non-switchabletwo-plug system having a GFI detection circuit connected to an 8-plugapparatus (4 main plugs and 4 extension plugs) in accordance with thepresent invention.

FIG. 20 illustrates a standard two circuit 200 switchable two-plugsystem, therefore requiring two GFI detection circuits, each connected a4-plug apparatus (2 main plugs and 2 extension plugs) in accordance withthe present invention.

While the invention has been described in terms of the embodimentsdescribed above, those skilled in the art will recognize that theinvention can be practiced with modification within the spirit and scopeof the appended claims.

1. A surface mountable, flexible, multi-purpose wiring comprising: aplurality of flat, elongated conductors, each conductor having a widthof 0.125 inches or more and comprising at least one conductive layerhaving a cross sectional height in the range of about 0.0004 to about0.0200 inches; a bonding material adjacent each said flat, elongatedconductor; and an insulation layer selected from the group consisting ofurethane, polyethylene and a fluoropolymer, said insulating layersurrounding said plurality of flat, elongated conductors and saidbonding material, said bonding material being bonded to said insulationlayer, wherein a combined cross-sectional height of said plurality offlat, elongated conductors, bonding material and insulation layer isless than about 0.050 inches, wherein said plurality of flat, elongatedconductors are separated by a distance in a range of about 0.125 andabout 0.6 inches. inches, and wherein the wiring may be folded back uponitself at any angle to accommodate angle changes on the surface of awall or ceiling.
 2. The multi-purpose wiring of claim 1, whereinopposite side edges of said insulation layer are tapered to allow saidwiring to blend in with a surface to which said wiring is mounted. 3.The multi-purpose wiring of claim 2, wherein said wiring bears oraccepts an adhesive tape, liquid or spray on either side of said wiringto adhere said wiring to a surface.
 4. The multi-purpose wiring of claim1, wherein said at least one conductive layer comprises at least oneconductive metal layer.
 5. A multi-purpose wire, comprising: a pluralityof elongated conductors, each conductor having a width of 0.125 inchesor more and comprising at least one conductive layer having a thicknessin a range of about 0.0004 to about 0.0200 inches; a bonding materialadjacent each said elongated conductor; and an insulation layer selectedfrom the group consisting of urethane, polyethylene and a fluoropolymer,said insulation layer surrounding said plurality of elongated conductorsand said bonding material, wherein a thickness of said wire is nogreater than about 0.050 inches, and wherein said plurality of elongatedconductors are separated by a distance in a range of about 0.125 andabout 0.6 inches. inches, and wherein the multi-purpose wire may befolded back upon itself at any angle to accommodate angle changes on thesurface of a wall or ceiling.
 6. The multi-purpose wire of claim 5,wherein said plurality of elongated conductors comprises a plurality ofconductors spaced apart in a generally parallel, coplanar relationship.7. The wire according to claim 5, wherein each elongated conductor insaid plurality of elongated conductors has a width in a range of about0.125 to about 1.5 inches.
 8. The wire according to claim 5, whereineach of said at least one conductive layer has a thickness in a range ofabout 0.001 to about 0.010 inches.
 9. The wire according to claim 5,wherein said plurality of elongated conductors comprises a range of 1 to6 conductors.
 10. The wire according to claim 5, wherein said at leastone conductive layer comprises a range of 1 to 5 conductive layers. 11.The wire according to claim 5, wherein said wire comprises a flexiblewire.
 12. The wire according to claim 5, wherein each of said at leastone conductive layer has a uniform width and thickness.
 13. The wireaccording to claim 5, wherein an application of said wire may be variedby varying one of a width of each elongated conductor in said pluralityof elongated conductors, a height of each said elongated conductor, anda number of conductive layers in each said elongated conductor.
 14. Thewire according to claim 5, wherein said at least one conductive layercomprises a range of 3 to 5 conductive layers, each conductive layerhaving a thickness of about 0.002 inches, and wherein said wire has athickness of about 0.012 inches.
 15. The wire according to claim 5,wherein said insulation layer comprises one of polyester, urethane,polyethylene and a fluoropolymer.
 16. The wire according to claim 5,wherein said insulation layer is flexible, paintable, and resistant toultraviolet light and joint compounds.
 17. The wire according to claim5, wherein said bonding material is bonded to an inner surface of saidinsulation layer.
 18. The wire according to claim 5, wherein saidbonding material comprises one of a thermal bonding material, adhesivetape, liquid adhesive and or a combination thereof.
 19. The wireaccording to claim 5, wherein said bonding material separates saidplurality of elongated conductors and maintains a safe dielectricdistance between said elongated conductors.
 20. The wire according toclaim 5, wherein said plurality of elongated conductors comprises 3conductors, wherein said at least one conductive layer comprises 3conductive layers, each conductive layer having a thickness of aboutabout 0.002 inches, and wherein said thickness of said wire is in arange of about 0.007 to about 0.050 inches.
 21. The wire according toclaim 5, wherein said wire has a width in a range of about 2.0 and about4.0 inches, wherein a thickness of said at least one conductive layer isin a range of about 0.0004 to about 0.0020 inches, and wherein adistance between said plurality of elongated conductors is in a range ofabout 0.2 to about 0.3 inches.
 22. The wire according to claim 5,wherein said plurality of elongated conductors comprises an alternatingcurrent (AC) ground conductor, split or unified, an AC neutralconductor, and an AC power conductor.
 23. The wire according to claim 5,wherein said wire comprises 110 V AC wire, wherein said plurality ofelongated conductors comprises a range of 3 to 5 conductors, and whereinsaid at least one conductive layer comprises a range of 1 to 5conductive layers.
 24. The wire according to claim 23, wherein saidplurality of elongated conductors comprises 2 AC neutral conductors, 2AC power conductors and 1 AC ground conductor, and wherein said wireaccommodates two circuits.
 25. The wire according to claim 23, whereinsaid plurality of elongated conductors comprises 1 AC neutralconductors, 2 AC power conductors and 1 AC ground conductor, and whereinsaid wire accommodates two circuits.
 26. The wire according to claim 23,wherein said plurality of elongated conductors comprises 1 AC neutralconductor, 1 AC power conductor and 1 AC ground conductor, and whereinsaid wire accommodates two circuits.
 27. The wire according to claim 23,wherein said wire has a width in a range of about 3.5 and about 4.25inches.
 28. The wire according to claim 5, wherein said wire comprises220 V AC wire, and wherein said plurality of elongated conductorscomprises: an AC neutral conductor and an AC power conductor, eachhaving a width in a range of about 0.4 and about 0.6 inches; and an ACground conductor having a width in a range of about 0.2 and about 0.4inches, and wherein of said at least one conductive layer has athickness of about about 0.002 inches, wherein said thickness of saidwire is in a range of about 0.012 to about 0.050 inches, wherein adistance between said plurality of elongated conductors is in a range ofabout 0.4 and about 0.6 inches, and wherein a width of said wire is in arange of about 3.0 and about 3.5 inches.
 29. The wire according to claim5, wherein said wire comprises one of loud speaker wire, telephone wire,cable television wire, low voltage wire and or under-surface lightingwire.
 30. The wire according to claim 5, wherein said plurality ofelongated conductors are separated by a distance in a range of about 0.2and about 0.3 inches.
 31. The multi-purpose wiring of claim 1 , whereineach conductor comprises a plurality of conductive layers.
 32. Themulti-purpose wiring of claim 1 , wherein the wiring is concealed on thesurface of the wall or ceiling by paint or wallpaper.
 33. The wireaccording to claim 5, wherein each conductor comprises a plurality ofconductive layers.
 34. A wire comprising: a plurality of conductors,each conductor having a width of about 0.125 inches or more andcomprising at least one conductive layer having a thickness no greaterthan about 0.0200 inches; a bonding material adjacent to said pluralityof conductors; and an insulation layer selected from the groupconsisting of urethane, polyethylene and a fluoropolymer, saidinsulation layer surrounding said plurality of conductors and saidbonding material, said bonding material being bonded to said insulationlayer, wherein said plurality of conductors are separated by a distancein a range of about 0.125 inches and about 0.6 inches, and wherein thewire may be folded back upon itself at any angle to accommodate anglechanges on the surface of a wall or ceiling.
 35. The wire of claim 34,wherein a total thickness of said plurality of conductors, said bondingmaterial and said insulation layer is less than about 0.050 inches. 36.The wire of claim 34, wherein said at least one conductive layer has athickness in a range of about 0.0004 inches to about 0.0200 inches. 37.The wire of claim 34, wherein a conductor in said plurality ofconductors has a width in a range of about 0.2 inches to about 0.8inches.
 38. The wire of claim 34, wherein each conductor comprises aplurality of conductive layers.